The development of herbal-based topical formulations has gained immense attention due to their safety, biocompatibility, and therapeutic efficacy in pain management. This review focuses on the formulation and evaluation of biphasic herbal pain relief sprays intended for musculoskeletal disorders, particularly sports-related muscle strains. A biphasic system consists of two immiscible phases that enhance solubility and rapid drug absorption through the skin. Herbal components with anti-inflammatory and analgesic activities, when formulated in biphasic systems, exhibit improved permeability and prolonged action. The study discusses the mechanism of herbal pain relief, formulation design, evaluation techniques, and comparative analysis with synthetic analgesic sprays. The combination of modern formulation technology with traditional herbal pharmacology presents a promising approach for effective, safe, and sustainable pain management.